Hyundai Genesis: Fuel Delivery System / High Pressure Fuel Pump Repair procedures

Removal
   
In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. Do not perform any repair work right after the engine stops.
1.
Turn the ignition switch OFF and disconnect the battery negative (-) cable.
2.
Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - "Release Residual Pressure in Fuel Line")
   
When removing the fuel pump relay, a Diagnostic Trouble Code (DTC) may turn up. Delete the code with the GDS after completion of “Release Residual Pressure in Fuel Line” work.
3.
Disconnect the fuel feed tube quick-connector (A) using a clip tool.
4.
Disconnect the fuel pressure control valve-connector (B).

   
Open the clamp cover (B) before disconnecting the quick connector. (If the clip is applied)

   
When removing the quick-connector with the clip removing tool (A), be careful not to damage the plastic clip (B).
If the clip is damaged, fuel line leak can occur due to a poor connection.

5.
Remove the intake manifold.
(Refer to Engine Mechanical System - "Intake Manifold")
6.
Remove the high pressure fuel pipe.
(1)
Remove the bracket mounting bolt (A).

(2)
Remove the high pressure pipe flange nut (A,B) in the order of A and B with the special service tool [SST No.:09314-3V100 or 09314-27130]
(3)
Remove the high pressure pipe bracket bolt (C).

7.
Remove the installation bolts (A) and then remove the high pressure fuel pump from the cylinder head assembly.
   
Unscrew the two bolts alternately by 0.5 turn. In case of fully unscrewing one of the two bolts with the other bolt installed, the housing surface of the cylinder head may be broken because of tension of the pump spring.

Installation
   
Be sure to check the low pressure fuel line quick-connector (A) is completely connected to the high pressure fuel pump until a confirmation 'click' sound is heard.
After connecting the low pressure fuel line connector, pull the hose to make sure that the low pressure fuel line is precisely installed in the high pressure fuel pump.
Be sure to install the high pressure fuel pipe (B) with the specified torques.
In case of leakage in the fuel line connection parts, a fire might break out. Must inspect all fuel line connection parts for any leakage with the ignition ON.

   
Before installing the high pressure fuel pump, position the roller tappet in the lowest position by rotating the crankshaft. Otherwise the installation bolts may be broken because of tension of the pump spring.
   
Be careful of foreign substances not to attach to the high pressure fuel pump head cover insertion unit.
   
Do not reuse the used bolt.
   
Do not reuse the used high pressure fuel pipe.
   
When tightening the installation bolts of the high pressure fuel pump, tighten the bolts alternately by 0.5 turn after tightening them with hand-screwed torque.
   
Install the component with the specified torques.
   
Note that internal damage may occur if the component drops. In this case, use it after inspecting.
   
Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove on the location where the protrusion (C) is installed.

1.
To install, reverse the removal procedure.
   
Use the special service tool [SST No.: (09314-3Q100) or (09314-27130)] to install the high pressure fuel pipe.


High pressure fuel pump installation bolt:
12.8 ~ 14.7 N.m (1.3 ~ 1.5 kgf.m, 9.4 ~ 10.9 lb-ft)
High pressure fuel pipe installation nut:
29.4 ~ 35.3 N.m (3.0 ~ 3.6 kgf.m, 21.7 ~ 26.0 lb-ft)
High pressure fuel pipe bracket installation bolt:
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

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Removal     • In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pre ...

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